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1G Transfer case input shaft seal leak

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9 T GSX

15+ Year Contributor
192
37
Jan 19, 2008
St.Pete, Florida
Have a strange situation with this seal leaking and looking to see if anyone had the same issue once upon a time and what fixed it?

Just had the T Case rebuilt so all parts/seals are brand new, there is no movement in any of the parts etc. Notable mention about this issue is that I didn't have this issue until the rebuild and the only 2 things that were changed were the 2 Shiny pieces :)

Also breaking in a clutch at the moment so shifting around 3000-4k.

Every time I filled T Case it was done by the tail shaft , installed with the car level, then I removed Fill bolt and let drain til fluid slowly was coming out.

1st Install: Drove the car for a few days then one morning noticed fluid under the T case, pulled T Case and saw the seal was pushed out on one side. Didn't think too much about it maybe something happened during rebuild, so I ordered another OEM seal and installed.

2nd Install: Drove car for a few more day then one morning noticed fluid in same area. Pulled T Case again, Same issue the seal was pushed out.

This time I was thinking maybe the breather bulb had some crap in it and was blocked not releasing pressure so I flipped the breather bulb inside out and noticed this flap, looks to be there on purpose I tried to pull this flap out a bit but wound up ripping it completely off. Reinstalled everything, Reused the seal

3rd Install: Drove car for a few miles looked under car and guess what was leaking. I quickly popped the hood and pulled the breather bulb to see if I could hear any pressure release, but no luck. This time I cleaned everything up again and put a little 3 bond (Gray) on the outer edge of seal and letting it sit overnight, Reused same seal. Just hoping that bit of silicone will keep the seal from popping out :pray: :idontknow:

Thought I had a picture of the seal and how it was popped out, Guess you'll just have to believe me.

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